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Troubleshooting DF-150E

12 Troubleshooting

12.1Troubleshooting Guide

The trouble shooting guide will help resolve many of the common problems
that can occur.

NOTE

If it is necessary to return the analyzer to the factory for repair,
refer to the Shipping the Analyzer section on page 59.

12.1.1

Problem Observations

Observation

Recommended Action

(See Table Below)

1. Analyzer reads low

A B D E H I J L

2. Analyzer reads high

A B C D E I J L

3. Analyzer output noisy

A E I L

4. Analyzer reads high with pump on

C L

5. Analyzer reads 0.00 or less at all times

D H K L

6. Slow speed of response

G C D E L

7. Electrolyte residue visible on the sensor

8. Electrolyte Condition indicator ON

E L

Table 8: Problems and Observations

Содержание DF-130E

Страница 1: ...Oxygen Analyzer DF 150E OPERATOR MANUAL...

Страница 2: ...be reproduced stored in a retrieval system or transmitted in any form or by any means including electronic mechanical photocopying recording or otherwise without prior written permission of Servomex C...

Страница 3: ...certificate of calibration assures your analyzer has been calibrated on gases that are traceable to NIST standards With proper maintenance your analyzer should remain calibrated for years For a fast...

Страница 4: ...ted to Servomex immediately All analyzers are shipped with the following Item Servomex Part Number One bottle of Hummingbird Brand E lectrolyte Blue Electrolyte Blue One bottle of Hummingbird Brand Re...

Страница 5: ...on 17 6 2 Electrolyte Condition Indicator 17 6 3 Analog Output 18 7 Options 19 7 1 Stab El 19 7 2 Alarms 20 7 2 1 Adjusting Oxygen Alarm Set Points 20 7 2 2 Alarm Relays 20 7 3 Pressure Regulators 21...

Страница 6: ...condary Electrodes Sec El Sec El 45 9 2 3 A B A B 45 9 2 4 Flow Switch Flow SW Flow SW Com 45 9 3 Pump Control Connector 45 9 3 1 Pump Control 45 9 3 2 Analyzer Control of a Remote Pump 46 9 3 3 Remot...

Страница 7: ...gure 12 Low Flow Alarm 24 Figure 13 Gas Correction Factor Adjustment 28 Figure 14 Panel Mount Dimensions and Layout 30 Figure 15 Panel Mount Cut out Dimensions 30 Figure 16 Rack Mount Dimensions and L...

Страница 8: ...non toxic non combustible sample gases only Servomex cannot be responsible for direct or consequential damages that result from using the analyzer with these gases 3 1 Explanation of Graphic Symbols...

Страница 9: ...ternal connections the sensor the electronics or when charging or draining electrolyte CAUTION Do not set up or operate this Oxygen Analyzer without a complete understanding of the instructions in thi...

Страница 10: ......

Страница 11: ...alyzer Range ppm DF 150E Model Range DF 150E Model 0 to 5 000 ppm 151 5000 0 to 25 151 P25 0 to 1 000 ppm 151 1000 0 to 10 151 P10 0 to 500 ppm 151 500 0 to 5 151 P5 0 to 100 ppm 151 100 0 to 1 151 P1...

Страница 12: ...ons etc Sensor with Stab El Neutralizes contaminants including acids such as CO2 H2S Cl2 NOX SOX etc See page 19 for concentration limits Sample Requirements Gas phase non condensing sample temperatur...

Страница 13: ...Specifications DF 150E 9 Figure 1 DF Series Oxygen Analyzer...

Страница 14: ......

Страница 15: ...aking Sample Gas Connections C Making Output Signal Connections D Powering up the Analyzer CAUTION To avoid damage to your analyzer Do not operate without electrolyte Do not use more than one bottle o...

Страница 16: ...ess steel outlet tubing option remove the nut from the outlet bulkhead fitting 7 Carefully slide the sensor out of the analyzer a few inches 8 Remove the quick disconnect at the top of the flowmeter S...

Страница 17: ...the bulkhead nut on the inlet gas connection on the rear of the analyzer NOTE After seating the nut finger tight use a wrench to turn it only an additional 10 degrees Do not over tighten the bulkhead...

Страница 18: ...han nitrogen you must set the indicated flow rate as shown in Table 1 Background Gas Flowmeter Setting scfh Argon 1 2 Ethylene 1 0 Nitrogen or Air 1 0 Carbon Monoxide 1 0 Methane 0 8 Hydrogen 0 3 Heli...

Страница 19: ...d with analyzers ordered for 220 VAC operation The power is supplied through a standard IEC 60320 C13 connector 2 For concentrations below 100 ppm it is useful to let the analyzer purge by letting gas...

Страница 20: ...ection on page 19 for information regarding Analog Output Scaling for 0 to 1 0 2 0 or 5 0 VDC 4 to 20 mA Output Stab El Acid Gas System Pressure Regulators and Flow Valves Gas Flow Switch Sample Pump...

Страница 21: ...of oxygen concentrations using calibration gases traceable to NIST 6 1 Stable Calibration The analyzer will remain calibrated as long as the sensor and its electrolyte are properly maintained Refer to...

Страница 22: ...dering are 0 to 1 VDC 0 to 2 VDC or 0 to 5 VDC See the sticker on the inside of the front door Figure 7 for the current setting of the analog output voltage The analog output is proportional to the ox...

Страница 23: ...Concentrations of CO2 are in percent One percent is equivalent to 10 000 ppm Table 2 Maximum Acid Gas Concentrations with Stab El in ppm Contact Servomex for recommendations on using the Stab El sens...

Страница 24: ...ocated between the alarm set point adjustments in the appropriate direction 3 Adjust the alarm knob while viewing the alarm value on the display 4 Release the toggle switch NOTE Alarm triggers are inh...

Страница 25: ...5 Amps or 30 VDC at 5 Amps resistive load 7 2 2 2 CE Qualified Analyzers Each alarm has an SPDT relay rated at 30 VDC at 5 Amps Exceeding this rating may cause damage to the analyzer Not to be used fo...

Страница 26: ...d grade DQ 1 micron 64005011 Table 3 Particle Filters The life of the filter element is dependent upon the nature of the sample gas Therefore it is difficult to recommend a filter element replacement...

Страница 27: ...w Alarm The Sample Gas Flow Switch is mounted downstream of the sensor The contacts will open when the sample flow falls below 0 12 lpm 0 26 scfh The Low Flow Alarm contacts are on the rear panel I O...

Страница 28: ...here the inlet pressure is less than 5 psi 7 8 Stainless Steel Outlet Tubing Stainless steel outlet tubing is available in place of the standard Tygon outlet tubing Stainless steel tubing is recommend...

Страница 29: ...ging from 4 to 20 mA represent oxygen concentrations from zero to the top of the currently selected range The 4 to 20 mA output is electrically isolated from all other analyzer outputs and from chassi...

Страница 30: ...2 in Ethylene Note that for light gases the dialed in percentage is for the light gas volume and for the heavier gases the dialed in percentage is for the volume of Nitrogen So if the control is turne...

Страница 31: ...dition there is further error introduced when correcting for a multi component background gas This may result in an additional 3 5 error Correcting the calibration for all combinations of background g...

Страница 32: ...umber may be adjusted by using the screwdriver pot located above the scale factor gas label This number ranges from 0 to 1000 corresponding to 0 to 100 0 of Nitrogen If the Scale Factor Pot is set to...

Страница 33: ...1 72 1 60 1 72 1 32 Butadiene C4H6 1 42 1 63 1 52 1 63 1 28 Acetylene C2H2 1 05 1 08 1 06 1 08 1 03 Hexane C6H14 1 75 2 13 1 94 2 13 1 50 Cyclohexane C6H12 1 57 1 86 1 71 1 86 1 38 Vinyl Chloride CH2C...

Страница 34: ...30 DF 150E Options 7 12Panel Mount Figure 14 Panel Mount Dimensions and Layout Figure 15 Panel Mount Cut out Dimensions...

Страница 35: ...Options DF 150E 31 7 13Rack Mount Figure 16 Rack Mount Dimensions and Layout Figure 17 Double Rack Mount Dimensions and Layout...

Страница 36: ...en making remote connections Refer to Table 6 and Table 7 for wire sizes and lengths Following are three remote sensor configurations and wiring diagrams Contact Servomex for additional information on...

Страница 37: ...Options DF 150E 33 Figure 19 Remote Sensor Bracket Mounting Holes 7 14 2 Sensor in NEMA 7 Enclosure Figure 20 NEMA 7 Remote Sensor Enclosure and Wiring Pin out...

Страница 38: ...ESS 75 NPT ELECTRICAL CONNECTION TO CONTROL ENCLOSURE FLOWMETER WITH INTEGRAL CONTROL VALVE OPTIONAL 5 25 133 35 3 00 76 20 7 25 184 15 2 50 63 50 44 11 11 THRU 4 PL 8 50 215 90 9 75 247 65 10 25 260...

Страница 39: ...OW SWITCH ROTOMETER FLOW CONTROL VALVE 11 25 285 62 OXYGEN SENSOR 10 00 254 00 SAMPLE INLET SAMPLE OUTLET SIGNAL OUTPUT AC POWER 7 42 188 58 2 96 75 30 4 71 119 75 1 93 49 02 2 75 69 85 7 00 177 80 9...

Страница 40: ...ions require higher temperatures In the event that the enclosure temperature must be adjusted follow the steps below 1 Obtain a temperature measurement device capable of measuring the desired operatin...

Страница 41: ...emp 75F 10F 25C 5C 45F 95F 7C 35C Table 5 Normal Operating Conditions 8 2 Condensation Liquid Slugs Like most gas analyzers the DF series operation will be compromised if there is condensation in the...

Страница 42: ...sed to determine the distance to a leak by noting the relationship between the time it takes for the analyzer to react to the change in gas flow rate 3 When flow sensitivity is observed check the exte...

Страница 43: ...stallation of gas valves to block the process gas flow and or direct inert gas flow to the sensor is highly recommended to minimize the possibility of damage to the sensor under process upset or maint...

Страница 44: ......

Страница 45: ...nnector is available on all versions of the DF Series however options indicated by labels on the connector may not have been included in the analyzer The Remote Sensor connector is not available on th...

Страница 46: ...an Alarm Condition when the analyzer is turned off or when power fails 9 1 1 1 Trouble Alarm If installed the Trouble Alarm is a combination of two alarms wired to a single output It is made up of th...

Страница 47: ...the front door Figure 7 for the current setting of the analog output voltage The analog output is proportional to the oxygen reading of the analyzer and on a three range analyzer will be scaled to the...

Страница 48: ...Not Use 9 2 The Remote Sensor Connector The Remote Sensor connector is not available on the DF 130 or on CE Qualified DF 150 analyzers A single shielded cable can be used for all signals on this conne...

Страница 49: ...the Low Flow switch internal of remote if equipped The contacts are rated at 120 VAC or 120 VDC at 0 5 A resistive 9 2 4 Flow Switch Flow SW Flow SW Com When a remote sensor is equipped with a flow sw...

Страница 50: ...wires in the pump cable should be attached to the pump connector on the rear of the analyzer The lowest pin is hot Pump Cable separate from sensor cable Distance in Feet Minimum Wire Size 0 500 22 AW...

Страница 51: ...per month Quarterly additions of Replenishment Solution are typical It is good practice to check the sensor level every 1 to 2 months initially to determine the rate at which the electrolyte level in...

Страница 52: ...ich it is calibrated If the analyzer was calibrated on a gas other than nitrogen the gas will be noted on the calibration log inside the front door and on a label below the display See the section on...

Страница 53: ...e for the analyzer to equilibrate 3 If necessary slowly turn the appropriate Span or Zero adjustment to obtain an oxygen reading that agrees with the Span or Zero calibration gas 4 Record the referenc...

Страница 54: ...he View Ref toggle switch Simply adjust the span pot as described above to make the display equal the Span gas value Figure 29 Calibration Adjustment with GSF installed 10 3Cleaning the Analyzer Befor...

Страница 55: ...ration in the sample gas KOH 4OH Sample Gas Cathode Secondary Electrodes Anode O2 1 3V Applied Figure 30 Schematic of DF Series Oxygen Sensor The cathode reaction uses 4 electrons from the 1 3 volt ci...

Страница 56: ......

Страница 57: ...e Analyzer section on page 59 12 1 1 Problem Observations Observation Recommended Action See Table Below 1 Analyzer reads low A B D E H I J L 2 Analyzer reads high A B C D E I J L 3 Analyzer output no...

Страница 58: ...age 12 Rinse the sensor with de ionized or distilled water prior to refilling and use only Hummingbird brand of electrolyte blue Allow the sensor to sit for 60 minutes before starting gas flow and the...

Страница 59: ...h a nominal flow of 1 0 to 2 0 scfh A regulator may be used to adjust the flow rate if there is no downstream restriction on the flow If the analyzer is not vented directly to atmosphere downstream co...

Страница 60: ...4 2 5 ppm 0 10 000 ppm 45 F 95 F 0 20 5 ppm 0 5 45 F 95 F 0 12 0 003 0 10 45 F 95 F 0 04 0 005 0 25 45 F 95 F 0 01 0 013 Table 10 Typical Output Drift by Analyzer Range 12 2 5 Flow Rate Effects on Sen...

Страница 61: ...573 Flow Meter w Valve 0 2 scfh 210852 Flow Switch all except 25 analyzer 210517 Flow Switch 25 analyzer only 210518 Fuse 5A Used for 110 VAC operation 210428 Fuse 100 mA Used in 4 20 mA option 210422...

Страница 62: ...e for the operating voltage of the analyzer The operating voltage for which the analyzer is set is marked beside the AC power connector All power input fuses are 5X20 mm 250 VAC IEC Sheet III Type T d...

Страница 63: ...he front door 2 Turn power off 3 Disconnect the electrical cable that runs to the sensor 4 Loosen the two knurled thumb screws in front of the sensor 5 Remove the bulkhead nut from the inlet gas conne...

Страница 64: ...s connection on the rear of the analyzer 6 Secure the two knurled thumb screws and verify that the sensor cannot move about in the analyzer 7 Re connect the electrical cable that runs to the sensor Dr...

Страница 65: ...yte before it is operated Use only Hummingbird type E LECTROLYTE BLUE Failure to do so will void the warranty NOTE If the electrolyte level is low only Hummingbird Brand Replenishment Solution needs t...

Страница 66: ...45 C 113 F Do not expose this analyzer to temperatures above 50 C 122 F Verify that the analyzer line voltage is set correctly Over pressurizing the analyzer can result in permanent damage to the sen...

Страница 67: ...itos Usen solamente E LECTROLYTE BLUE Si no cumple con esto anular su garant a PRECAUCI N Si el nivel de electr litos est bajo solo se tiene que a adir al sensor agua destilada o desionizada No le a a...

Страница 68: ...lasificada como NEMA 4 No use este analizador en temperaturas m s altas de 45 C 113 F No exponga el analizador a temperaturas de mas de 50 C 122 F Verifique que la l nea de voltage del analizado est c...

Страница 69: ...lectrolyt E LECTROLYTE BLUE Falls Sie dies nicht tun wird die Garantie ung ltig VORSICHT Falls der Elektrolytstand niedrig ist mu dem Sensor nur destilliertes oder entionisiertes Wasser zugef hrt werd...

Страница 70: ...lysator nicht bei ber 45 Grad Celsuis 113 Grad Fahrenheit Setzen Sie diesen Analysator keinen Temperaturen ber 50 Grad Celsuis 122 Grad Fahrenheit aus berpr fen Sie ob die Stromspannung des Analysator...

Страница 71: ...electrolyte E LECTROLYTE BLUE L inobservance de cet avis annullera la garantie PRECAUTION Si le niveau de l lectrolyte est bas il suffira d ajouter au senseur de l eau distill e ou non ionis e N ajou...

Страница 72: ...os classifi NEMA 4 Ne pas op rer cet analyseur une temperature au dessus de 45 C 113 F Ne pas exposer cet Analyseur une temperature au dessus de 50 C 122 F V rifier que la ligne de voltage est regl co...

Страница 73: ...igeno A Plus L inosservanza di questa precauzione risulter nell annullamento della garanzia ATTENZIONE Se il livello del elettrolito si abbassa si dovrebbe aggiungere nel sensore solamente acqua disti...

Страница 74: ...si deve operare l analizzatore ad una temperature al di l di 45 C 113 F Non si deve esporre l analizzatore ad una temperature al di l di 50 C 122 F Verificare che l analizzataoare sia allegata a una c...

Страница 75: ...3 Fire 0 Reactivity 1 Persistence 0 NFPA Ratings scale 0 4 Health 3 Fire 0 Reactivity 1 Potential Health Effects Eye Contact Causes severe eye burns May cause irreversible eye injury Contact may caus...

Страница 76: ...e Hazard Not applicable Extinguishing Media Not Combustible Select extinguishing media appropriate to the surrounding fire conditions Protective Equipment Wear appropriate protective clothing to preve...

Страница 77: ...ompletely soluble in water 104 50 C 3 50 C Not applicable Not flammable Not applicable 1 15 16 1 mm Hg 200 C 10 Stability Reactivity Chemical Stability Stable Conditions Materials to Avoid Incompatibl...

Страница 78: ...and local regulations 14 Transportation Information Shipping Name Hazard Class UN Number Packaging Group US DOT Potassium Hydroxide Solution 8 UN1814 II IATA Potassium Hydroxide Solution 8 UN1814 II...

Страница 79: ...the chemicals are listed European International Regulations European Labeling in Accordance with EC Directives Classification Corrosive Hazard Symbol C EC Number 215 181 3 Risk Phrases R35 Causes seve...

Страница 80: ...THE SUBSTANCE Trade Name Hummingbird Brand Replenishment Solution RS A Manufacturer Servomex Corp 4 Constitution Way Woburn MA 01801 1087 USA Tel 1 781 935 4600 Emergency Contact USA 1 800 424 9300 I...

Страница 81: ...htly closed Suitable for any general chemical storage area Protect from freezing May react vigorously with some specific materials Avoid contact with all materials until investigation shows substance...

Страница 82: ...ushed to sewer If material becomes contaminated during use dispose of accordingly Dispose of container and unused contents in accordance with federal state and local requirements 14 Transportation Inf...

Страница 83: ...e Seller be liable for consequential damages NO PRODUCT IS WARRANTED AS BEING FIT FOR A PARTICULAR PURPOSE AND THERE IS NO WARRANTY OF MERCHANTABILITY Additionally this warranty applies only if i the...

Страница 84: ......

Страница 85: ...Pump 25 Remote 41 Remote Sensor 44 Sample Gas 13 Sensor 59 coulometric 51 E Electrolyte adding 13 17 chemical reaction 51 Condition Indicator 17 low levels 17 Safety 61 Error 27 F Filters 22 flow con...

Страница 86: ...Power 44 Pressure Regulator 21 Process Upsets 38 Oxygen Shock 38 Pump 24 46 recommendations 55 Remote Control 46 Switch 25 Pump Control 45 Pump Control 25 purge 15 R Rack Mount 31 Range 43 Remote Oper...

Страница 87: ...Index DF 150E 83 U Upsets Oxygen Shock 44 V Voltage 15 46 checking 15 W Warranty 79...

Страница 88: ...2552 EUROPE Europe and Africa Tel 31 0 79 330 1580 Fax 31 0 79 342 0819 Toll Free 00800 7378 6639 LATIN AMERICA MEXICO Tel 55 11 5188 8166 Fax 55 11 5188 8169 ASIA PACIFIC Tel 86 0 21 6489 7570 Fax 86...

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